Method of replacing the transfer cores of yarn packages with resilient replacement cores

ABSTRACT

A method for transferring a package of yarn supported by a transfer core to a replacement core including the steps of inserting the replacement core into the transfer core, removing the transfer core relative to the package of yarn and the replacement core, holding the package of yarn during withdrawal of the transfer core, and permitting the yarn and replacement core to interengage in completing the transfer of the yarn onto the replacement core. There is also provision for the steps of compressing the resilient core to reduce its size, compressing the package of yarn, and anchoring the replacement core against axial displacement.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of application Ser. No. 276,318, filedJuly 31, 1972 (now U.S. Pat. No. 3,833,974 granted Sept. 10, 1974).Application Ser. No. 276,318 is a continuation-in-part of applicationSer. No. 105,920, filed Jan. 12, 1971 (now U.S. Pat. No. 3,681,007granted Aug. 1, 1972).

BACKGROUND OF THE INVENTION

The invention relates to an apparatus for processing yarn packages fordyeing and, in particular, to an apparatus for replacing a relativelyimpervious transfer core of a yarn package with a dye penetratingforaminous core.

Yarn that has been processed for dyeing may be in the form of bulkedcontinuous filament thermoplastic yarn such as polyester, nylon orcellulose triacetate yarn, as well as spun yarn, such as direct spunrayon having residual shrinkage of up to 20 percent when exposed toconditions of high humidity or when immersed in aqueous solutions, oracrylic yarn having high residual shrinkage by reason of unrelaxed heatsensitive fibers in the yarn. This yarn is generally wound into packageform about a cardboard or paper transfer core or tube such that theouter portion of the package is at substantially a desired bulk levelwhereas the innner portion is somewhat below this level. As disclosed inU.S. Pat. No. 3,425,110, the bulk level of the inner portion of thepackage may be increased by simultaneously removing the cardboardpackage core while inserting a perforate dye core or tube of apredetermined smaller diameter than the cardboard core. The innerportion of the highly stretchable yarn then contracts (and gains bulk)about the perforate core.

Apparatus for replacing the cardboard core with a perforate core isdisclosed in the aforesaid patent. However, such apparatus is subject tovarious drawbacks. The apparatus employs a vertically movable mandrelupon which is placed a perforate core. Upon actuation, the perforatecore is pushed downwardly into engagement with a cardboard core in theyarn package, whereupon the continued downward movement causes theperforate core to push the cardboard core completely out of the package.Owing to the pressure and movement of the entering perforated core,there is a tendency of the yarn package to come apart and undulydistort. The apparatus is only able to process yarn packages singlywhereas multiple package processing is more desirable for economy andefficiency purposes. Further, owing to the fact that both the cardboardtransfer core and perforated dye core simultaneously move through theyarn it has been found necessary to sandwich a paper or knit sleeve orsock between the yarn and the transfer core to serve as a bridge orshield during transfer. Without the sleeve it has been observed thatsome of the strands of yarn become trapped between the ends of thetransfer core and the dye core during the operation, thereby disturbingthe continuity of the yarn.

As set forth in the above-referenced application Ser. No. 105,920, ithas been found that the above drawbacks and disadvantages are overcomeby placing a replacement dye core within the cardboard transfer core andthereafter pulling the cardboard core out of the yarn package to permitthe package to contract around the replacement core. Apparatus forperforming such a process has been proposed as set forth in theco-pending application. While achieving satisfactory results, furtherimprovements have now been provided for simultaneously processing atleast two yarn packages in continuous operation. Provision is also madefor effective handling and disposing of the cardboard transfer core.

SUMMARY OF THE INVENTION

It is, therefore, a primary object of the invention to provide anapparatus adapted to continuously process multiple yarn packages byreplacing the impervious transfer core of each yarn package with aforaminous replacement core of a predetermined smaller diameter.

It is another object of the invention to provide an apparatus of theforegoing type for continuously processing package cores and thereafterdisposing the transfer cores.

The above and other objects are satisfied by an apparatus including anendless conveyor supported by a frame and a core replacement stationadjacent the conveyor. A plurality of spaced apart yarn package supportsare arranged on the conveyor. Indexing means are also present forsequentially indexing each of the supports at the core replacementstation. A mechanism associated with the feed station is utilized forpulling the transfer core from each of the yarn packages conveyed to andindexed at the feed station. Also present at the feed station are meansadapted to cooperate with the pulling means for preventing axialmovement of the package during removal of the transfer core.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will become apparent fromthe following detailed description of the invention which is to be takenin conjunction with the accompanying drawings illustrating a preferredembodiment of the invention in which:

FIG. 1 is an end elevational view illustrating the core transferapparatus of the invention;

FIG. 2 is a front plan view taken along line 2--2 of FIG. 1;

FIG. 3 is an exploded view illustrating the core pulling mechanism ofthe apparatus;

FIG. 4 is an enlarged fragmentary sectional view showing the corepulling head before grasping the transfer core with hold down platerestraining the yarn package;

FIG. 4a is an enlarged fragmentary sectional view showing the corepulling head after grasping the transfer core with the hold down platerestraining the yarn package;

FIG. 5 is a fragmentary enlarged sectional view showing the core pullingassembly after removal of the transfer core from the yarn package; and

FIG. 5a is a fragmentary enlarged sectional view showing removal of thetransfer core from the core pulling assembly.

DETAILED DESCRIPTION

As illustrated in FIGS. 1 and 2 the core transfer apparatus of theinvention includes frame 10 upon which is carried three spaced drivenchains 12. A conventional chain drive (not shown) drives the endlesschains through sprocket wheels 14 located at opposite ends of the frame.A series of spaced apart conveyor plates 16 are carried in parallel rowsby the chains 12.

Each conveyor plate 16 carries a yarn package support assembly 18. Asillustrated in the drawings and particularly FIGS. 1, 3 and 4, supportassembly 18 includes annular horizontal spacing plate 20 supported fromconveyor plate 16 by vertical pillars 22. Protruding through a centralhole in spacing plate 20 is vertical mandrel 24 which is threaded intoconveyor plate 16. An intermediate plate 17 cooperates in supporting thelower end of core 26.

A foraminous replacement core such as a coil spring or a perforatedplastic tube of smaller diameter than the original cardboard transfercore 26 is placed over the mandrel as shown in FIG. 2. It is alsocontemplated that replacement core 28 be in the form of a spring, whichis designed in such a way that the lacing when empty gives an effectivediameter to the spring which is larger than the inside diameter of thecardboard core 26. However, upon insertion of the spring 28 into thecore, the nature of the lacing is such that the spring can be compressedwithin the cardboard core. It is virtually a hand operation necessitatedby the fact that the diameter of the spring before insertion is largerthan the inside diameter of the transfer core. The operator merelycompresses the spring to permit it either to be forced into the transfercore or in the alternative for the transfer core to be forced over thespring. The reason for such a tight fit, is to permit little if anyspace to exist between the inside core of the yarn and the outsidesurface of the replacement core or spring. The replacement core 28extends through the orifice in spacing plate 20 and rests on conveyorplate 16 (see FIG. 4). Yarn package 30 is supported by spacing plate 20.In order to further arrest the movement of the replacement core duringthe transfer core pulling operation, a horizontally disposed hole orchannel 32 is placed in the base portion of the mandrel. Prior to thecore pulling operation a reciprocable rod 34 illustrated in FIG. 3 andcarried at the core pulling station is inserted through the replacementcore 28 into the channel by a conventional air or hydraulic actuatedcylinder 36.

A core pulling station 38 is provided for cooperating in removing thetransfer core 26 from the yarn packages 30. As illustrated in FIGS. 1-3,the station preferably includes first and second core pulling assemblies40, 40'. Each pulling assembly has associated therewith a yarn packagerestraining sub-assembly 42 and a transfer core removing head assembly44.

The yarn restraining sub-assembly 42 operates to arrest any possiblemovement of the yarn package 30 during transfer core removal; and itincludes an annular hold down plate or pressure pad 46, which, asillustrated in FIG. 4, is adapted to abut the upper end of the yarnpackage during core transfer. Improper spacing of the yarn windings oncore 26 are overcome by the downward movement of the plate 46, thebottom of which stroke insures that the yarn is in firm contact with thespacing plate 20. The relationship of the spacing plate to the elevationof the cores 28 is a constant which is maintained for uniform spacing ofthe yarns on the spring. It has been found desirable to have the plate46 slightly compress the package (see FIG. 4), in order to loosen thegrip of the yarn on the cardboard tube 26, and permit easier withdrawal.The axial compression of cross-wound packages, results in somerelaxation of the yarn, and consequent easier withdrawal of thecardboard core 26. Slight compression also provides a uniformcontainment between the spacing and the restraining plates, thedistances between the plates being somewhat less than normal distancebetween the ends of the yarn on an untreated package. The hold downplate has a central orifice extending therethrough to permit thetransfer core to be pulled therethrough. The hold down plate 46 has asupport collar 48 attached to its upper surface. The support collar hasa central orifice of sufficient diameter to permit split ring or jawclamp 76 to extend therein during engagement with the transfer core 26.

The hold down plate 46 is attached to a reciprocating mechanism whichpermits the hold down plate to be raised and lowered as desired duringthe sequential operation of the apparatus. The hold down plate actuatingmechanism includes an air actuated piston disposed within cylinder 52connected to one face of the pulling assembly. A reciprocating rod 54 isvertically disposed from the cylinder and is attached to hold down platebushing 56. Plate bushing 56 is a generally rectangular metal plate towhich is bolted or connected support collar 48. During movement of thehold down plate, bushing 56 reciprocates vertically along travel rods 58and 60. The travel rods are supported by rectangular bottom stop plate62 which is connected to pulling assembly 40' by means of support 64.

Movement of the hold down plate 46 is arrested at the lowermost verticalposition by bottom stop plate 62 and at its uppermost position by topstop 66. A pair of holes are provided in the plate bushing 56 to permitthe travel rods to extend therethrough.

In FIGS. 3-5, pulling head assembly 44 is illustrated. A pair of pullinghead assemblies 44 are mounted at opposed sides of pulling station 38(See FIG. 1). Each pulling assembly is in vertical axial alignment withthe hold down plate 46 of the associated yarn restraining subassembly42. Pulling head assembly 44 includes chuck 68 which is adapted tointernally and frictionally engage transfer core 26. Cylindrical collet70 has a central orifice extending therethrough and is adapted tofrictionally engage the upper portion 72 of pilot pin or chuck 68 andrest on chuck shoulder 74. A collet or jaw clamp 76 is concentricallydisposed about collet 70 and chuck 68. Clamp 76 has a split skirt 78adapted to be compressed inwardly by external pressure. As illustratedin FIG. 4, a cylindrical space is provided between the inner surface 80of split skirt 78 and the bottom surface 82 of chuck 68. The spacing issufficient to permit the transfer core to be disposed therein duringengagement thereof. The gripping assembly formed from clamp 76, collet70 and chuck 68 is secured together by means of bolt 84 and spacer 86. Apair of stabilizing rods 88 extend from the upper face of collet 70 andextend through travel plate 90.

An annular locking collar or constriction ring 98 is adapted tofrictionally engage split skirt 78 and compress the skirt inwardlytoward chuck 68 to frictionally engage transfer core 26 as illustratedin FIG. 5. For this purpose, the constriction ring should be of somewhatlarger diameter than the widest portion 100 of the split skirt 78. Apair of integral wings 102 extend outwardly in opposite directions fromthe uppermost portion of the constriction ring. In order to permitreciprocation of the constriction ring between a lowermost position asillustrated in FIG. 5 adjacent the bottom of split skirt 78 to anuppermost position as illustrated in FIG. 4 in engagement with travelplate 90, travel rods 104 are provided. Rods 104 are threaded into wings102 at their lowermost portions and are connected at their uppermostportions through travel plate 90 to air cylinders 106. Air cylinders 106are adapted to reciprocate travel rods 104 to a lowermost and uppermostposition in a preselected sequential manner.

Gripping head assembly 44 is connected by means of bolts (not shown) totravel plate 90 and thusly, moves therewith. Air cylinders 106 are alsoconnected to travel plate 90 for movement therewith. Further,constriction ring 98 is connected to air cylinders 106 through travelrods 104 and is also adapted to move with travel plate 90. However,constriction ring 98 is adapted to independently move in reciprocalfashion with respect to travel plate 90 by means of the air cylinders.In order to permit the gripping head assembly 44 and constriction ring98 to move from a first position as illustrated in FIG. 2 above the yarnpackage to a second position wherein the chuck 68 and clamp 76 are infrictional engagement with the upper edge of the transfer core 26,travel plate 90 is connected to piston rod 108. Piston rod 108 is thereciprocating rod for air cylinder 110 which is in vertical alignmentwith the central axis of locking collar 98 and the vertical axisextending through the gripping head assembly 44. As illustrated in FIG.1 air cylinder 110 is connected to the pulling assembly support 40' bymeans of horizontal supports 112, 112'.

An aligning shaft 114 provides additional alignment support for thegripping head assembly 44 when it is in the lowermost position adjacentthe transfer core 26. Aligning shaft 114 is connected at its lowermostportion to travel plate 90 and is adapted to move therewith. Aligningshaft 114 also extends through support 112' which serves to preventlateral movement of this shaft when in its lowermost position.

An air jet 116 is provided fpr blowing the transfer cores 26 into acollecting bin (not shown). The air jet is on the pulling assembly 40such that when the gripping head assembly 44 is in its withdrawnuppermost position and the transfer core 26 is released, it can blowthis core into the collecting bin.

In operation, as illustrated in FIG. 2, a spring or perforatedreplacement core 28 is placed over mandrel 24 by the machine operator.Next, the yarn package containing the transfer core 26 is placed overthe mandrel 24 until it rests on spacing plate 20. Another core and yarnpackage is placed on the aligned companion mandrel on the chainconveyor. Next the conveyor chain is energized. The mandrel loadingprocedure is repeated for the remaining mandrels as they turn to theirupright position. Timing cams (not shown) may be employed actuatingconventional four-way solenoid valves which, in turn, energize the aircylinders. Thus, the timing cam for each core pulling assembly 40 or 40'is adapted to actuate its associated four-way solenoid valve in responseto movement of the conveyor chain in order to actuate sequentially aircylinder 52, air cylinder 110, air cylinder 106 and air cylinder 36, aswill be discussed in further detail hereinafter. This controlling meansor indexing means 120 is shown schematically in FIG. 2 and is of thegeneral type which is well-known to those skilled in the conveyor art.As a pair of mandrel supported yarn packages approach the core pullingstation 38, they are indexed and placed in vertical alignment with thegripping head assembly 44 and hold down plate assembly 46. At thispoint, both the hold down plate assembly and gripping head assembly arein their raised position. Next, the holddown plate air cylinder 52 isactuated to permit the holddown plate to descend into frictionalengagement with the top surface 118 of yarn package 30. Simultaneouslytherewith or shortly thereafter, pulling head air cylinder 110 isactuated thereby driving travel plate 90 downwardly to permit thegripping head assembly 44 to descend about the top end of transfer core26. After the chuck 68 has descended into the transfer core and theclamp 76 has been concentrically disposed about the core 26, the aircylinders 106 driving the constriction ring 98 are activated to lowerthe rings into compressing engagement with the widest portion 100 ofclamp split skirt 78. This movement drives the split skirt toward thechuck thereby causing gripping of the upper end of the transfer core 26.Prior to this time or before the transfer core is pulled from the yarnpackage reciprocal rod 34 will have been directed in the channel 32 ofthe mandrel by air cylinder 36 to prevent the replacement core 28 frommoving with respect to the yarn package during the core pullingoperation.

Next, air cylinder 110 is actuated to raise the gripping head assembly44 to pull the transfer core 26 out of the yarn package. The holddownplate air cylinder 52 is then actuated to release the yarn package.Simultaneously therewith or sometime shortly thereafter, air cylinders106 are actuated to raise travel rods 104 to lift the associatedconstriction ring 98 to the position as illustrated in FIG. 4 at whichthe transfer core 26 is released from the clamp 76. At this time, aircylinder 110 is actuated again to raise the assembly 44 about 2 inchesto permit the core 26 to fall freely. Simultaneously therewith, the airjet is actuated to blow the released core 26 into the collection bin(not shown).

Thereafter, the entire operation is repeated with the next pair of yarnpackages being indexed at the pulling station.

It will be obvious to those skilled in the art that variousmodifications may be made to the apparatus hereinbefore described. Suchembodiments are considered to be within the scope of the invention. Theabove invention is not be limited except as set forth in the followingclaims:

I claim:
 1. A method for transferring a package of yarn supported by arigid imperforate transfer core to a foraminous, resilient dye core ofpredetermined diameter comprising, in sequence, the steps of:a.compressing the resilient core to reduce its size; b. inserting theresilient core into the transfer core; c. anchoring the resilient coreagainst axial displacement; and d. axially removing the transfer corerelative to both the package of yarn and the resilient core.
 2. Theinvention in accordance with claim 1 wherein the compression of theresilient core is released to facilitate its interengagement with thepackage of yarn following removal of the transfer core.
 3. The inventionin accordance with claim 2 wherein the transfer core is gripped andthereafter pulled axially in removing it from between the yarn packageand the resilient core.
 4. The invention in accordance with claim 3wherein the package of yarn is held stationary during the withdrawal ofthe transfer core.
 5. A method for transferring a package of yarnsupported by a transfer core to a replacement core comprising, insequence, the steps of:a. inserting the replacement core into thetransfer core; b. anchoring the replacement core against axialdisplacement; c. compressing the package of yarn; d. gripping andthereafter pulling the transfer core axially in removing it from betweenthe yarn package and the replacement core; and e. holding the package ofyarn stationary during the withdrawal of the transfer core.
 6. Theinvention is accordance with claim 5 wherein the transfer core isejected and removed to another location after removal from the yarnpackage.
 7. A method for transferring a package of yarn supported by atransfer core to a replacement core comprising, in sequence, the stepsof:a. inserting the replacement core into the transfer core; b. grippingand thereafter pulling the transfer core axially in removing it frombetween the yarn package and replacement core; c. holding the package ofyarn stationary during the withdrawal of the transfer core; and d.permitting the yarn and the replacement core to interengage incompleting the transfer of the yarn onto the replacement core.
 8. Theinvention in accordance with claim 7 wherein the replacement core isanchored against axial displacement during the removal of the transfercore.
 9. The invention in accordance with claim 7 wherein thereplacement core is a foraminous dye penetrating core.
 10. The inventionin accordance with claim 9 wherein the foraminous dye penetrating coreis a perforated plastic tube.